Since it's always great to hear about what people are doing to their trucks I thought I would make a thread about it. Try to limit your response to just the current thing you are addressing on the truck. I'll start the thread off in my next post.

Currently I am working on rebuilding the pedal assembly in my truck as I noticed the brake pedal moves when I push the clutch and vice versa. Upon removal and inspection what I thought to be bushing related was actually the pedal assembly bracket just flexing due to poor reinforcement. I ended up welding a bracket to support the right side and welded the seams to help give the assembly strength where there were no spot welds.

I ended up painting the assembly while it's out since it was all rusty metal and looked terrible. I also replaced the plastic bushings with a new kit from Ford $12 since I had it out, but the originals were actually fine even with 250,000 miles on them.

I still need to order a rod end to replace the eyelet on the end of the clutch master cylinder rod as mine is worn oval. Hoping all this helps keep my gears from grinding as I was losing 1/2 to 1" in my pedal throw from the above issues. I will post some pictures of the finished product when completed.

WOW! I need to know how you did this! My '92 has about 1/2 of clutch total because the hole that the bushing goes in is wallowed out. A reinforcement with a new bushing guide would fix the whole thing.

You would need to remove the assembly but it really is not hard to do. Unbolt the master cylinder for the clutch and the brake booster. I removed the steering column also as it gives a lot more room to work, which is 4 bolts and 1 on the steering shaft.

With the assembly out it is much easier to work on and I would not recommend welding it inside the vehicle anyway.

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